Control for resistance line welding machines



y 30, 1940. v F. M. BECK 2,209,805

I CONTROL FOR RESISTANCE LINE WELDING MACHINES Filed Dec. 31, 1938 asi- 7 InventOP O Francis M. Bec 1 MA, QB A by fi zifitorneg Patented July 30, 1940 PATENT OFFICE azoasos con'raor. roa RESISTANCE use wsnnmc moms Francis M. Beck, Schenectady, N. 1., assignor to General Electric Company, a corporation of New York Application December 31, 1938, Serial No. 248,761

6 Claims.

My invention relates to an improvedcontrol for resistance line welding machines in which anelectrode is positioned relative to the work by the return movement of a travel carriage which, under the influence of its reversing control, does not uniformly come to the same position at the end of a return stroke following a work stroke.

It is an object of my invention to provide a control which gives the best possible weld location commensurate with the variations in return movement of the travel carriage.

It is a further object of my invention to provide a control in which the flow of welding current is initiated through the agency of a directional switch which is responsive to the change in direction of travel of the travel carriage occurring between its return stroke and its work stroke.

Further objects of my invention will become apparent from a consideration of the welding apparatus illustrated in the attached drawing, Fig. 1 of which diagrammatically illustrates a welding machine and its control, and Fig. 2 01' which is'a view partly in section of the directional switch forming part of the control illustrated in Fig. 1. a

Resistance welding apparatus embodying my invention is particularly useful for fabricating refrigerator evaporators formed of suitably shaped plates provided with depressions that cooperate with one another in forming header and conduit passageways. The plates of such evaporators are joined to one another on opposite sides of the depressions forming the conduit passageways by line welds and it is desirable to have these line welds begin as near as possible to.the header. As shown in Fig. 1, these line welds are made by an electrode II which travels along the evaporator II which is supported in a predetermined position on a travel carriage II which is reciprocated relative to the electrode I l. The electrode ll may be provided as shown in the drawing with a cut away portion which clears the header oi the evaporator H. A plurality of welds may be made at the same time by using a plurality of electrodes II;

The forward and return movement of travel carriage H is controlled by a fluid motor whose cylinder l3 encloses a piston which is connected by a piston rod H to an arm I! forming part of the travel carriage, Oil, or a similar operating fluid, is supplied to the opposite ends of cylinder i3 on opposite sides 01 its piston by a pump it through a pressure control valve 11, a master control valve '8, a direction control valve [9 and speed control valves 2.. The operating fluid is discharged from cylinder I! through valves 26 and I! through exhaust pipes 2i. Pressure control valve l1 and master control valve ll are also provided with exhaust pipes 2 i. Master control valve l8 and direction control valve i9 are electrically operated valves and are provided with operating windings 22, 23 and 2|. Master control valve i8 is biased to a closed position when its operating winding is deenergized. Each of the speed control valves 29 includes an adjustable throttling valve for controlling the rate of flow of oil to cylinder l3 and a check valve which bypasses this throttling valve and permits the tree discharge of oil from cylinder l3 to exhaust pipes 2|. By an adjustment of valves the desired rate .of forward and return movement of the travel carriage may be set. 1

Electrode It is supported in a yoke 25 which is connected by a rod 28 to a piston located in an air cylinder 21. Admission of air to the opposite ends of this air cylinder on opposite sides of the piston is controlled by an electrically operated air valve 28 which has an operating winding 28. Air valve 28 is normally biased to a position in which air is supplied to cylinder 21 to raise electrode it from evaporator ll. When electrode l0 has been forced into engagement with evaporator H and exerts a desired welding pressure thereon, a switch 30 which is responsive to air pressure, will close its contacts II.

The forward and return movement of travel carriage i2 is controlled by a limit switch 32 having an operating member 33 which is located in the path of travel of adjustable stops it and 35 attached to the travel carriage. This limit switch is provided with contacts 36 which are closed at the end of the return stroke'of travel carriage l2 and with contacts 31 which are closed at the end of the work stroke of this travel carriage. Limit switch 32 has a snap action and its movable contact is held in engagement with contacts 38 or IT through the agency of a cam 38 which is biased by a spring 39 into engagement with a. cooperating cam 40 located on its operating member 33.

A welding operation is initiated by the closing of a switch 4| which connects the operating winding 42 of a relay 4! to the source of alternating current 44, 45 through conductors 48, contacts 36 of limit switch 32, and conductors ll, 48, 49 and 50. This relay is provided with holding contacts 5| which maintain the energization of its operating winding 42 after it has operated and closed these contacts. This relay is also provided with control contacts 52 which control the energization of the operating winding 88 of a relay 84. When relay 48 closes its contacts 52 the operating winding 58 of relay 84 is connected across the source of supply 44, 48 through conductor 48, contacts 38 of limit switch 82, and conductors", 55, 88 and 88.

Relay 54 is provided with control contacts 81, 88, 58 and 88. When relay 84 is deenergized, its contacts 51 and 88 are closed and its contacts 58 and 59 are opened and when relay 54 is energized its contacts 51 and 88 are opened and its contacts 58 and 88 are closed. When contacts 57 of relay 84 are closed, an operating circuit for the winding 22 of master control valve I8 is completed from the source 'of supply 44, 45 through conductor 48, contacts 81 of limit switch 82, conductors 8|, 82, 83, 84 and 88. When contacts 88 of relay 84 are closeda control circuit for the operating winding 24 of the direction control valve I9 is completed across the source of supply 44, 45 through conductors 85, 88, 81, 58 and 58. This will cause direction control valve l9 to take a position for admitting operating fluid to the right end of cylinder l8 and for exhausting fluid from the left end of this cylinder so that the fluid motor of which the cylinder l8 forms a part will move travel carriage i2 to the left. When contacts 58 of relay 84 are closed, an operatin circuit across the source of supply 84, 45 is completed for the operating winding 22 of direction control valve it as well for the operating winding 29 of air valve 28. The operating winding 23 of direction control valve i9 is completed through conductors 88, 88, 89, 81, 88 and 58. The operating winding 29 of air valve 28 is completed through conductors 18, 1|, 88, 81, 58 and 58. The

closing of contacts 58 of relay 54 in conjunction with the closing of contacts 3| of pressure switch 38 and the closing of the contacts of directional switch 12 connects across the sourceof supply 44, 48', the control circuit of a switching device 13. This circuit is completed through conductors I4, 18, 18, 11, I8 and 88. Switching device I3 may be an electromagnetic contactor, a thyratron control panel or the like, which controls the connection of the primary 18 of the welding transformer to the source of supply 44, 48. Best results are obtained by using a quick acting switching device. The terminals of the secondary 88 of the welding transformer are respectivelyconnected to electrode l8 and travel carriage l2 1 of the welding machine.

It will be noted that the operatingwinding tacts 3| of pressure switch 38 through conductors 14, I5, 63, 64 and 58.

The construction of the directional switch" of Fig. 1 is illustrated in Fig. 2 of the drawing.

This switch is provided with a member 8| biased to a ilxedposition in a forward direction by a 3 spring 82 and moved from this position an amount varying with variations of the return stroke ofx travel carriage l2 through the agency of an arm 83 which is mounted on the travel carriage and,

engages the projecting end of member 8 I. A second member 84 comprising an assembly of wash- Member 84 by reason of the slot 92 in member 8| through which the bolt 89 of member 84 extends. Member 84 travels with member 8| in a forward direction until member 84 engages the frame 83 and is then displaced relative to member 8| until the parts assume the position illustrated in Fig. 2. When member 8| travels to the left as viewed in Fig. 2, member 84 travels therewith and engages a lever 94 which moves to the left a pre determined distance determined by the limited travel of the operating member 85 of a switching device 96. Lever 94 may be attached to and supported by frame 93 of the directional switch. When the travel of lever 94 is arrested by the limited movement of operating member 95 of switching device 98, member 84 is then displaced relative to member 8|. Frame 93 and the limited movement of operating member 95 of switching device 96 constitute stops limiting the travel of member 84 with member 8|.

It is to be noted that the construction of the directional switch is such that on the return movement of travel carriage I2, switching device 88 is operated, that is, opened, irrespective of the variations in return movement of the travel carriage which are compensated by the relative movement of members 8| and 84. As soon as the travel carriage moves in a forward direction, member 84, travelling with member 8| immediately operates switching device 98, that is, allows the switching device 98 to close.

Where very critical adjustments are required, switching device 85 may be of the type shown in United States'Letters Patent No. 1,960,020-Philip K. McGall, granted May 22, 1934. This type of switch can be operated by movement of its operating member through a very small range of travel, for example, .001 or .002 of an inch. The criticalness of switching device 98 may also be controlled by the position of its operating member 85 relative to operating lever 94 forming part of the directional switch. 3

The utility of the welding apparatus diagrammatically illustrated in Fig. 1 of the drawing will best be understood by considering its operation.

The parts of the welding machine and the con-' trol therefor are shown in Fig. l in the positions they assume at the end of a return stroke following a work stroke during which a line weld has been made in the evaporator The operatorinitiates the welding operation by closing start switch 4|. This energizes the operating winding 42 of relay 43 by connecting of master control valve I8 is connected across the source of supply 44, 48 upon the closure. of conj 'ductor 41, switch 4|, and conductors 48, 49 and 58.

it across the source of supply 44, 45 through conductor 46, contacts 38 of limit switch 32, con- Once relay 43 has operated it is held in its closed position through a holding circuit completed through its contacts which are in shunt to switch 4|. The operation of relay 43 also com- :pletes a circuit through its contacts 52 which energizes the operating winding 53 of relay 54 by connecting it across the source of supply 44, 45 through conductors 48, contacts 38 of limit switch 32, conductor 41, contacts 52 of relay 43, and conductors 55, 58 and 58. The operation of relay 54 completes a circuit through its contacts 58 and 59. The closing of contacts 59 energizes the.

' operating winding 23 of direction control valve i9 and the operating winding 29 of air valve 28. The operating winding 23 of direction control valve I9 is connected across the source of supply 44 and 45 through conductors 85, 88 and 69, contacts 59 of relay 54, and conductors 61, 58 and 58. The operating winding 29 of air valve 28 is connected across the source of supply 44, 45 through conductors l and H, contacts or relay 54, and conductors 61, 58 and 50. The operation of direction control valve I! as a result of the energization of its operating winding connects the right-hand end of cylinder II to exhaust pipes 2| and the left-hand end of this cylinder to the pressure line in series with master valve l8 and pressure control valve H. The operation of air valve 28 admits air to the upper part of cylinder 21 forcing its piston downward which in turn applies welding electrode ll to evaporator ll. When thedesired pressure has been obtained between electrode I0 and evaporator ll, pressure switch operates closing its contacts 3|. The closure of these contacts connects the operating coil 22 of master valve l8 across the source of supply 44, through conductor 14, contacts I of pressure switch 30, conductors 15, i3, 64 and 50. Thus, as soon as the desired welding pressure is obtained between welding electrode ill and evaporator ll, master valve It opens admitting operating fluid to the left end of cylinder ll moving its piston therein and with it travel carriage i2 toward the right.

As soon as travel carriage l2 moves to the right directional switch 12 operates and completes in conjunction with pressure switch 10 whose contacts 3| have already closed, and relay 54, whose contacts 58 have also closed, the operating circuit for switching device I3. This circuit is completed from one terminal 44 01' the source of supply through conductor 14, contacts 3| of pressure switch 30, conductor 15, contacts 58 of relay 54, conductor 15, directional switch 12 and conductors 11, 18 and 50. The completion of this control circuit will operate switching device 13 which then connects the primary 1! of the welding transformer to the source 0! supply 44, 45.

The welding operation proceeds as travel carriage l2 moves to the right during its work stroke until stop on the carriage engages and operates limit switch 32. When this limit switch is operated it opens its contacts 36 and closes its contacts 31. The opening of contacts 26 deenergizes relay 43 which in turn deenergizes relay 54. When relay 54 is deenergized it opens its cont acts 58 and I9 and closes its contacts 51 and 60. The opening of its contacts 59 deenergizes the operating winding 23 of directional valve l9 and the operating winding of air valve 28. The ensuing operation of air valve 28 causes the electrode Ill to be raised from the work by the admission of air below its piston and the exhaust of air from above its piston. As a result of the conditions thus established, the pressure switch 30 opens its contacts 3i but this does not deenergize the winding 22 of master valve I! which has meanwhile been connected by the closing of contacts 31 of limit switch 32 across the source of supply 44, 45 through conductors 46 and CI, contacts 51 of relay 54, and conductors 52, 63, 64 and 50. At about the same time that the operating winding 23 of directional valve I8 has been deenergized by the opening of contacts 59 of relay 54, the operating winding 24 of this valve is connected across the source of supply 44, 45 through contacts 60 of relay 54, this circuit being completed through c0nduct0rs and 66, contacts III of relay 54 and conductors 61, 56 and 50. The operation of direction control valve I! under the action of its operating winding 24 connects the left end of pressure cylinder I3 to the exhaust pipe 2| and the right end of this cylinder to the pressure supply through master control valve l8 and pressure valve II. This will cause the piston in cylinder it to move to the left and move with it travel carriage l2 until stop 35 on the travel carriage engages and operates limit switch 32 closing its contacts 38 and opening its contacts 31. The opening or contacts 31 deenergizes the winding 22 of master control valve I8 which then closes and arrests the return movement of travel carriage l2. Due to variations in the operations of limit switch 32 and master control valve it it is apparent that travel carriage l2 will not uniformly come to rest in the same position after each work stroke.

At the end of the return stroke the several parts of the welding apparatus illustrated in Fig. 1 will assume the positions there illustrated and another welding operation may then be initiated by closing switch' 4|.

It will thus be seen that by the use of directional switch 12, preferably in combinations with a high speed switching device such as a thyratron control, I obtain the best possible weld location commensurate with variations in the return movement of travel carriage i2. Irrespective of the amount of variation in return movement of the travel carriage as soon as a work stroke is initiated, welding current is supplied to the electrodes and the resulting weld is located as closely as it is possible to locate it inthe desired position. In those controls previously employed where a limit switch has been used to control the flow of welding current, it has been necessary to set the limit switch to accommodate the minimum return movement of the travel carriage and in doing this all the welds are spaced from the desired location an amount determined by the minimum return movement of the travel carriage. This I have avoided by the use of a directional switch which accommodates variations in return movement of the travel carriage and which is responsive to changes in the direction of travel of the travel carriage occurring between its return stroke and its work stroke.

My invention is equally applicable to those welding machines in which the electrode is supported by a travel carriage which is traversed over the work. Any form of friction switch of of the type above described which is responsive to changes in direction of travel carriage movement may be substituted for the particular switch illustrated in Fig. 2 of the drawing. By a proper adjustment of the parts of the directional switch, the welding current may be applied after any desired predetermined movement of the travel carriage.

The particular reversing control for the travel carriage above described may be variously modified without departing from my invention which is applicable to any machine in which an electrode is positioned relative to the work by the return movement of a travel carriage which, under the influence of its reversing control, does not uniformly come to the same or a desired position at the end of a return stroke following a work stroke. In the application of my invention above considered, the reversing control functions to return the travel carriage to substantially the same position at the end of each return stroke but reversing controls that function in a manner to secure predetermined variations in return movement of the travel carriage to position the electrode in predetermined desired positions after each work stroke may also be used without departing from my invention.

Furthermore a line welding machine such as above described may be .used for performing spot welding operations by suitably interrupting the supply of welding current. In fact, a plurality of overlapping spot welds usually constitute a line weld such as obtained in the above referred to evaporator and by properly controlling the switching device 13, especially if it is a thyratron control, any desired spacing of the spot welds usedin making a line weld may be obtained.

Inview of the above disclosure of one embodiment of my invention, other embodiments thereof will readily suggest themselves to those skilled in the art" and I intend to cover in the appended claims all .those variations and modifications of" my invention which fall within the true spirit and scope thereof.

What I claim as new and desire to secure by Letters Patent of the United States, is:

1. Resistance welding apparatus wherein an electrode is positioned relative to the-work by the return stroke of a travel carriage comprising, a reversing control for saidtravel carriage which does not uniformly return said travel carriage to the same position at the end of a return stroke following a. work stroke, means including a switch for initiating the flow of welding current to said electrode, and means responsive to the change in direction of travel of said travel carriage occurring between its return stroke and its work stroke for operating said switch.

2. Resistance welding apparatus wherein an electrode is positioned relative to the work by the return stroke of a travel carriage comprising, a reverslng control for said travel carriage which does not uniformly return said travel carriage to the same position at the end of a return stroke following a work stroke, means including a switch for initiating the flow of welding current to said electrode, and means responsive to the change in direction of travel of said travel carriage occurring between its return stroke and its work stroke for operating said switch, said means including a member operated by said travel carriage through a range of travel varying with variations in the return stroke of said tr vel carriage, a second member frictionally engaging said first-mentioned member and travelling therewith through a portion of the travel of said first-mentioned member, means for displacing said secondmentioned member relatively to said first-mentioned member before said first-mentioned member reaches the ends of its travel, and means responsive to the movement of said second-mentioned means during its travel with said firstmentioned means for operating said switch.

3. Resistance welding apparatus wherein an electrode is positioned relative to the work by the return stroke of a travel carriage comprising, a reversing control for said travel carriage which does not uniformly return said travel carriage to the same position at the end of a return stroke following a work stroke, means including a switch for initiating the flow of welding current to said electrode, and means responsive to the change in direction of travel of said travel carriage occurring between its return stroke and its work stroke for operating said switch, said means including a member biased to a fixed position in a forward direction and moved by said travel carriage from said fixed position anamount varying with the variations in the return stroke of said travel carriage, a second member frictionally engaging said first-mentioned member and travelling therewith through a portion of the travel a of said first-mentioned member, a lever supported at one end and having its free end in the path of travel of saidsecond-mentioned member during the movement of said first-mentioned member in response to the return movement of said travel carriage, a stop engaging said lever and limiting its travel as well as the travel of said second member, a second step engaging said secand member and limiting its travel with said firstmentioned-member during the movement of said first-mentioned member in response to the forward movement of said travel carriage, and means engaging said lever intermediate its ends and responsive to a limited movement of said lever immediately before and immediately after it engages and disengages said first-mentioned stop for operating said switch.

4. In combination, a travel carriage, a reversing control for said travel carriage which does not uniformly return said travel carriage to the same position at the end of a return stroke following a work stroke, a control circuit including a switch, and means responsive to the change in direction of travel of said travel carriage occurring between its return stroke and its work stroke foroperating said switch, said means including a frictional drive between driving and driven members, means for limiting the range of travel of said driven member relative to the range of travel of said driving member, and means reversing with the directions of travel of said travel carriage for moving said driving member in reverse directions through a range of travel which is greater than the variations in the return movement of said travel carriage. I

5. In combination, a travel carriage having a forward movement and a variable return movement, a member operated by said travel carriage through a range of travel varying with variations.

in the return movement of said travel carriage, a second member frictionally engaging said firstmentioned member and travelling therewith through a portion of the travel of said first-men-v tioned member, means for displacing said secondmentioned member relatively to said first-mentioned member before said first-mentioned member reaches the ends of its travel, and means responsive to the change in direction of travel of said travel carriage occurring between its metum movement and its forward movement. said means embodying a control circuit including a switch operated by the movement of said secondmentioned member during its travel with said first-mentioned member.

6. In combination, a travel carriage having a forward movement and a variable return movement, a member operated by said travel carriage through a range of travel varying with,variations in the return movement of said travel carriage, means responsive to the change-in direction of travel of said travel carriage occurring between its return movement and its forward movement. said means embodying a control circuit including a switch having an operating member whose range of movement is limited, a stop spaced from said operating member of said switch an amount less than the travel of said first-mentioned member, and another member frictionally engaging said first-mentioned member and movable therewith between said switch operating member and said stop until displaced relative to said firstmentioned member in its forward and reverse travel by said stop and said operating member of said switch. I

FRANCIS M. BECK. 

